Foot casts and process of making the same



Nov. 24, 1959 A. E. MURRAY 2,913,771

` Fo'oT CASTS AND PROCESS 0F MAKING THE SAME Original Filed Oct. 27, 1954 5 Sheets-Sheet l Nov. 24, 1959 Original Filed pct. 27, 1954 A. E. MURRAY FOOT CASTS AND PROCESS' OF MAKING THE SAME 5 Sheets-Sheet 2 INVENTOR ./lZanEMurray ATTORN Nov. 24,41959 A. E. MURRAY 2,913,771

FooT cAsTs AND PROCESS oF MAKING THE SAME Y Original Filed Oct. 27, 1954 5 Sheets-Sheet 3 INVENTOR EMz/Lrray @www W ATTORNEY United States Patent Alan E. Murray, New York, N.Y.

Original application October 27, 1954, Serial No. 465,109. Divided and this application May 6, 1955, Serial No. 506,435

1s Claims. (ci. 1st-55.05)

My invention relates particularly to foot casts and the method of producing them, wherein greater accuracy and control in making the same is attained.

This application is a division of my copending application upon Interdigital Toe-positioners, Casts, Footwear, Process of Making the Same and Products Thereof, Ser. No. 465,109, filed October 27, 1954.

An object of my invention is to make possiblethe production of casts which more accurately and faithfully conform to the actual foot shape of the wearer of shoes made therefrom.

A further object is to provide foot casts which retain the true position of the toes and metatarsal region of the foot as a result thereof.

Another object is to eliminate the previous residual difficulties encountered at times in securing an actual reproduction of the true shape of the feet.

Further objects of -my invention will appear from the detailed description ofthe same hereinafter.

While my invention is capable of embodiment in many different forms, for the purpose of illustration I have shown only certain forms thereof in the accompanying drawings, in which:

Fig. 1 is a plan View of one form of a toe-positioner or toe-lock;

Fig. 2 is a similar plan view of a smaller-sized toepositioner or toe-lock;

Fig. 3 is a plan view of a foot showing the position of said toe-lock thereon;

Fig. 4 is a vertical transverse section of the same taken on line 4 4 of Fig. 3; f

Fig. 5 is a vertical longitudinal section of a bread pan containing a spherical supporting plate with a rectangular outline;

Fig. 6 is a vertical transverse section of said spherical supporting plate taken on line 6--6 of Fig. 5;

Fig. 7 is a plan view of a felt sheet partly broken away, carried on said plate;

Fig. 8 is a side elevation of said bread pan having instead therein plaster of Paris covered by burlap;

Fig. 9 is a plan view of the pan, plaster and burlap of Fig. 8;

Fig. 10 is a rear elevation of one of the inserts having ice sized insert 1 for the top of the foot, as shown in Fig. 1, or I may make a smaller insert 2, shown in Fig. 2, which are made the same except for the fact that in the insert 2 a greater portion is trimmed from around the same, as hereinafter described. Also, the procedurel in making said inserts 1 and Z is substantially the same for the left foot 3 and the right foot, respectively. For this purpose, the foot 3 is placed on any desired surface, which may be a flat surface of a table top, while the wearer may be seated on a chair located on the table and with the weight of the foreleg resting on the table top. Preferably instead, however, 1 may rest the foot 3 on any chosen portion of a ball-shaped surface 4, as shown in Fig. 4, in accordance with the procedure of supporting the feet as described in my copending application upon Method of Making Footwear and Products Thereof, Ser. No. 385,094, tiled October 9, 1953, now Patent No. 2,742,717, in order to provide convex supporting surfaces at either side of the top of the ball surface for the respective left and right feet, the said portions of which'surfaces approximately conform to the `underneath concave curvatures of the archesor metatarsal regions of the respective Thereupon, I place over the front portion of the foot, as shown in Fig. 3, a piece of jersey cloth 5, which is the material from which underwear is made, that is to say which is very stretchable into any desired 3dimensional shape. T he cloth 5 is preferably woven on a tubular, or convex, form so that the threads in the Weaving take a circular or curved direction when being woven.

Thereupon, I prepare a mud made of thickened neoprene latex or any other latex, which may be thickened top and bottom members, for the top and bottom of the foot;

Fig. 11 is a plan view of the insert of Fig. 10;`

Fig. 12 is a plan view of each of the two pieces of jersey cloth for forming said insert;

Fig. 13 is a plan view of a toe-positioner sock used in place of the jersey cloth shown in Fig. 12;

Fig. 14 is a plan view of the insert shown in Fig. 10, showing Ventilating holes therein; and

Fig. 15 is an elevation partly in section of av cast made with surgical wrappings. Y

In carrying out my invention, il preferably make a toepositioner or insert such as the toe-lock shown in Fig. 1 or 2. Referring to Figs. 1 to 4, in making the said toepositioner as an interdigital toe lock, I may make a full as set forth in my application Ser. No. 385,094 aforesaid, or in my Patent No. 2,568,291 referred to therein. Of course, any rubber, or artificial rubber, latex ofa similar character could be used instead, to make the mud. llnto an amount of the said thickened neoprene latex sufficient to form a positive cast, `I ,knead a quantity of diced felt, such as 1A?" cubes, orv granules ofl a smaller size, to produce a consistency about like that of cottage cheese; The said felt is preferably of the cheap gray flooring felt, which is V generally ymade from mill ends or waste and which is comprised generally of 40% wool and 60% cotton waste comprising the various impurities commonly present in such waste. However, instead of the said felt, other types of felt could'be used, or wool flocks or cotton ocks or' rayon ocks, etc. Also, therewith, I may or may not introduce into the thickened latex and felt granules any desired quantity of a filler, such as wood flour. This, for example, may be a pine wood flour or any otherl one or more kinds of wood our. This mud, with or without' the filler, may have the proportions of the three different materials widely varied to produce the desired consistency, but, for example, it may be comprised of one part by volume of the thickened latex, one part by volume of the dicedfelt, and one-half part by volume of wood flour.

The jersey cloth 5 is now pressed down between the toes to the surface 4, with the aid of a dull tool or table knife, into the recess between the b ig toe and the next toe, and while so pressed down a quantity of the mud 6 is forced, with the ngers, into the cloth within the recesses from above. The other three toe recesses are then lled in, in a similar way, one after another, until the cloth 5 andthe mud 6 is extruded beneath and towards the adjacent underneath portions of therespective toes, as shown in Fig. 4. This results in the production of two wrinkles 7 and V8- at the rear of each of the toe recesses, which are thereupon snipped olf with a pair of scissors. Some of the thickened latex is then applied on top ofthe cloth 5 extending outwardly to a marginal link 9, asshown in Fig. 3, which extends considerably Patented Nov. 24, 1959 beyond the outer margins of the front of the foot, so that this entire portion of the cloth 5 becomes completely saturated with the latex. Thereupon, I shake some powdered plaster ofParis all over the top of the impregnated cloth 5. Then, I apply a second, or top, piece of jersey cloth of the same size and character as that above referred to, which is placed over the top of the cloth 5 and the interdigital mud toe-separators 6, and mold the same downwardly with the ngers, all over the top at the front metatarsal portion of the foot and toes. The latex, meantime, will have completely saturated the top cloth 10. Then, with a table knife, I mold the jersey cloth pieces 5 and 10 underneath the toe ends and over and beyond the opposite edges of the foot,`as shown in Fig. 4. Next, I brush over the top of the said cloth 10 some thickened latex sothat the cloth becomes wel! impregnated therewith. A fan, or hair dryer producing a current of heated air, is then directed onto the said foot support for about fifteen minutes, whereupon the latex and powdered plaster of Paris will have become partly set, and sufficiently dried for the insert to hold its shape. k

The foot is now carefully 'removed from the insert. This can be readily done because of its elasticity, and in spite of the extruded enlarged lower portions located between the toes, as shown in Fig. 4. The fan, or hair dryer, is now directed onto the support for about twelve hours, in which time-the'same will have become substantially completely' set and capable of being worn on the foot. Alternatively, if it is desired to further con form the insert to the foot in any given instance, it can be replaced and worn on the foot within less than the said twelve hours to completely shape it and intimately conform it to the interdigital recesses and in complete conformation with the other foot contours.

The insert thus made, before being returned to the foot for general or permanent wear, may be cut off around the line of the marginal indentation 11, as shown in Fig. 4, on both sides of the foot and in front of the toes so as to produce the full size support 1, as shown in Fig. 1. However, if a smaller insert is desired, instead, it may be cut along a line 12, as shown in Fig. 3, or at any other desired outline thereon. Also, if desired, the extruded portion 6 between the toes, as shown in Fig. 4, may be cut off somewhat along a line or level 13, as shown in Fig. 4, or to any other desired degree, while still leaving downward portions thereof extruded between the toes laterally in the interdigital spaces.

As an alternative procedure, the nal insert may be made of sponge rubber, especially as sponge rubber is more elastic and compressible than `the materials of which the inserts 1 and 2 have been made. For this purpose, I may make initially an insert as above described, after which any desired negative plaster ofParis cast may be made of said insert. Then I finally pour into the said plaster negative a moldable rubber or a sponge rubber material or composition which, when solidified carries therein throughout the body of the rubber small cavities, having the usual compressibility of sponge rubber.

As a further modification of the latter alternative method, instead of making the initial foot support of the two pieces of jersey cloth 5 and 10 and -the mud 6, I may make the initial model by means of a moulage or by forming a plastic mold of Plastelenef winch is a non-setting mixture of clay and a mineral oil, or of the dental molding material commonly used by dentists, doctors, artists, etc., for making molds of the different portions of the human body. When the initial mold is made as a positive plaster cast, then a negative can be made therefrom, after which the sponge rubber insert can be molded therein, as above described.

The insert thus made by Vany of the above procedures will provide an effective support for the foot by, in effect, suspending the toes from the upper surface of the foot, and can be worn on the foot vinside the shoe, with or without a sock, even when the shoe is non-fitting or oversized, while preserving the position of the toes and the shape of the foot, or it may be worn within a sock without a shoe, especially as the support will effectively resist the usual tendency of the sock or shoe or both to produce undesirable displacements of the toes. Also, the inserts 1 and 2, while locking the toes in their true relation, will. nevertheless, permit bending and free movement of the toes during the exercise thereof. A

The said toe-lock 1 or 2, but preferably the smaller -toe-lock 2, may now `be used for making a more accurate cast of the foot on which a shoe is to be made. For this purpose, the toe-lock 2 may be placed on the foot so as to hold the toes in position accurately, and the foot with the toe-lock thereon may then be used to produce a very accurate negative cast, followed by the making of an accurate positive cast therefrom, in accordance with the procedure described, for example, in my Patent No. 2,177,734, granted December 24, 1939. When the positive plastic cast is obtained therefrom the toe-lock 2 may be placed on the cast and a molded shoe built therefrom in accordance with kany of the procedures in my previous patents. In wearing the shoe the wearer will, preferably, wear the said toe-lock 2 on the foot beneath a sock within the shoe.

Or, as an alternative method of making a cast, I can proceed as follows: In making a negative cast in the following way, I am enabled to tighten up the tissues of the foot without losing the relative shape of the different partsof the foot. This procedure draws the foot together While keeping its approximate shape, due to the presence of a toe-positioner or toe-lock. For this purpose, the foot may be supported upon an appropriate portion of the curvature 4 of the ball or spherical surface, such as is described in my copending application Serial No. 385,094 aforesaid, having a radius of approximately 36. For convenience, I may provide, as shown in Figs. 5 and 6, a spherical surface 14 selected from the surface of said sphere 4 which conforms most closely to the curvatureof the under side ofthe particular foot, and the said surface may be embodied in a rectangular metal plate -15 having a cavity 16 beneath the same for lightness. The said surface 14 is, for instance, chosen for `the left foot of the wearer having the toe position near the left end of Fig. 5 and the heel position towards the right end thereof. This rectangular plate 15 is preferably made so 'as to fit within the bottom of a rectangular bread pan 17 having upwardly flaring sides. A rectangular piece of felt 18, as shown in Fig. 7, is now provided, made from approximately 1A thick felt, such for instance as therfelt above referred to, or other brous materials. The felt piece 18 having 'now been placed on the surface 14, a layer of sand 19, about M3 thick, is scattered on top of the felt 18. Thereupon, the procedure of making the negative cast, followed by the making of a positive cast, may be carried out in accordance with the procedure in my patent aforesaid, No. 2,177,304. However, instead, in making a negative cast while the foot is rested on the said 19 supported by the felt 18, a little sand is preferably placed between the toes to prevent the toes from becoming locked to the plaster. With a spoon, I now apply the plaster of Paris and water'niixture having a consistency of heavy cream, around the foot down to where the foot meets the sand 1.9 and so as to extend slightly beneath'the undercut line and extending up to above the ankle joint. Weakening vertical marks are 'now made thereon by scoring both sides of the plaster of Paris on opposite sides of the foot opposite to the ankle joint so'that this part of the cast can be separated into two pieces later. When this plaster is hard, the foot is raised together with the upper portion of the negative cast or baifle thereon. A second pan of the same kind as the pan 17 is now prepared, filled with the said plaster of Paris cream to a level somewhat higher than the level of the lsend 19 in the rst pan 17,

andthe foot, having thereon the upper negative` cast is transferred to said second pan while the operator presses this `negative upper cast and the foot down into thelsecjond pan. During this operation, the foot will retain its ball-like underneath curvature 'and will transfer the shape thereof `to the plaster lower half Ofthenegativefin'the second pan.` This negative, whenremoved in threeseparate portions Vfrom lthe foot, is` then reunited andfused for making a plaster f Parispositive, thereinwand hen a shoe may be built on this jaositiive.4 j r However, it isV one of .the purposes of my invention t0 produce a castfwhichfray be constructed either for a" soft foot ora vhard Ifoot, as ldesired. `Acastlfands l'ioe like those just described maybe suitable for wearvbyfa hard foot. However, in making a cast especially adapted for a soft foot, I may produce the cast in such a way as to exert a pressure equally throughout onthe footlby applying pressure to the exterior 'ofYV the Aplaster it is setting, which-may be produced `b ymakingna negative plaster cast with the toe-lock 2` or 1, if desired. l'Accordingly, I provide a bread pan of the'same ltype` asth`e pan 1 7, andI prepare a large bas in,"aboutA l2`rin-`di' ameter, containing some of the said plaster of Paris cream; but which 4is preferably salted by-jthe additionfthereto of about a half a tablespoon full of ordinary salti VThen I pour about one third of this salted plaster of L'Paris cream intothe-fbread pan, The footfwithhthe toellocl on it, preferably, powdered withtalcum powder, is then lowered Vin to the'plasterof Parisin the bread 'panV to approximately the 'unlercutnline of the foot. N ow, the

.plaster of :Parisis: leveled oit ati the undercutif-line with@4 `4 negative ,cas-ting" Vf the" foot to'hbe i accomplished ."Sirn'ull tarieously. Accordingly, the leveled'offplaster'fParis,

as above referred to, is'then 'covered over"withf `about eight or more Small piecesof 'riewspaperg20juntilfthe` entire-surface ofthe plaster off- Paris vis"coveredthere- Y by," although the '"pieces"of paper-`need not accurately plaster is -still mobile -and has r not yet- 'setf` by Vcarrying -'the two'ends of the burlap 2.1'- to` the front'around the ankle from therear of the 'plasterfand lapping over at the front-thereof,` as shown' in Figs.- Sfrand 9. Thereupon, while Vthe plasterisfstill inthe formable condition,.before it has set, Ipat4 down on-"tlztetop of the burlap, with the hands, all over' the wet plaster. vThis sup` plies pressure. which is substantially.' equalizedV all i overl theexterior of 'the lfoot. fHoweve'r, the `degree ofthe pressure may be "controlled and applied" to ,alvarying zext'ent,"`acc or'ding to,` theii amount offpresslre :desired: to be applied to theexteriorf'of the foot, :This Aresultsinfapplying a tightness tothe foot tissuesLinthe case of `soft feet, and the ldegree 'of tightnessfappliedy may bei checked according to the tightnessifeltrbyftheeperson'-onfwhose foot the .castiis being-madewlThis can bemodulatedac.-

cording' to the softness of the particular foot andzaccoljdi ing to theA purpose to be r attained; p For iinstanc'eg-.in :the case or`.sportswear,` and especiallyl in thewcaseyof Vskating shoes V4oi dancing ,shoes which vare tobe made.; on -the plaster positive cast made'ffrom said negative, the'tight* nessof ,thenegative cast onfthe footlwill be increasedV to provide'the type roff,footwear, desired in theccaseof/ while the relative shape of the foot, and particularly the :toes and adjacent metatarsal part of thelfoot, is retained.

e L footfand; even 4No. 2,404,483, granted July 16,`l946.

Just before the plaster of Paris becomes rock-like in hardness, which is approximately five or six minutes from the time the plaster isapplied to the foot, the burlap 21 is stripped off and,' owing to the two Vertical scorings or indentations made'at the opposite sides of the cast, the, upper negative cast, is made ready to be split into two pieces, a front upper portion 22-and a rear upperportion 22a. After an additionaliiveminutesthe mass ofplaster becomes very hard and the foot is then lifted up, together with the plaster andV the pan, having the front piece 22 and the rear piece 22a and an underneath cast 23 of the plaster supported by the foot.` The pan isv then tapped lightly on the edge, which results Ain the pan, carrying the bottom piece y23 of the negative cast, falling away from the foot.` With'a screw driver, the forward and rear pieces 22 and 22a'of the cast can now be `separated atthe` vertical scorings-onthe sides the-wf. u v

In order' to make the positive cast therefrom," the toelock 2 is takenioif the foot and stuck intoV its proper place in its recessin theinside of the forward piece 22 of the negative cast? The negative cast is now fastened together with rubber bands or Duco cement. This negative cast is then iished out with a water solution of silicateof soda to provide 'a separation surface, from the plaster of the positive cast to be made therein. Thereupon, the plaster of`Paris cream is poured into the negative cast while vibrating the latter slightly and the plaster is then allowed'to harden. A positive cast is thus obtained havirigallthe actualdetails of the foot, including the correctlymaintained position of the toes, which has beenunalteredbyany involuntarylinclination of'the foot produce a` movement oftheftoes rduring the casting operationt? 4 f A With this truly accurate positive cast any typeuof footwen'in accordance with anyof my 'previous processes or ways ofiproducingshoes, sandals, etc.',vmay bel made, for examplethe thin type ofsandals shown vin rnyPatent Also,"ins tead, ifdesiredI mayl makeatoe-lock, such as the toe-lockmlorthe toe-lock 2, on this completely ac curate 'positivec`a4st',fl3yfl the methods described herein- Furthermorefif desired, havirigmade-this cast toe- `lock`, I can apply the Jtoe-lock tothis castand' then make a s hoe by any ofthe molding methods as set forth in my previous patents or application'sfor VLetters Patenti` In such a shoe, the toe-lock 1 or 2 .co`uld-fbe worn next to thefoot with 4the stocking outsidethe toe-lock, and in' this way `any displacement of the toes, 'due to sock tension, could be entirely eliminated. .Infthis way,'mainteriance of theIfoot-in its correct position` is insured in the shoe even rmore effectively than if the shoe were molded on the foot: withoutthe `aid hof the toe-lock` or toe-positioner. In other words, the toealock becomes thethird member, V`in adr'lition tothe sock and shoe, which iills up the un- I occupied. space'in the shoe vat suchpl'aces as might not have been made to conform completely to `the foot `when the Shoe-is molded on the foot without" the `aid of the toe'- lock. This willbeapparent from the factlthatfif afcomplete -shoe were molded .with all the toe-lock `contours molded into the shoe, the shoe coul'dlneitherV be placedy on 'theifootnorwithdrawn from the` foot.` In other words, the physiologicalaccuracy of the toeLlock comparedlto the shape'ofthe'toes and the 'metatarsal portion ofthe footjissubstantially the same `as if the person werewalk.-

ing in a terrain of sand or soft mud,which induced the formation of the -interdigitali-contours; in the course of natural evolutionf ij' Furthermore,a-composite'insert 24can now be made on "the foot, or on "any cast made as 'above with the toelock lor 2,V following theprocess in mypatent referred lto above, No.` 2,177,304', or withthe modifiedcasting procedure involving the said-toe-lockl or 2 in which the mound of plaster, sho'wn 'in Figs. 8 'and 9, is "subjected Afoot margin.

7 to pressure to tighten up the tissues of the foot, which composite insert may embody said toe-lock V1 or2 as well as a pyramid 2'5. i The. pyramid 25 may be carried by a lower ap or member 26 which is located opposite to the interdigital-extrusions 6 Vbetween therespective toes, carried on an upper flap or member 27 of the toelock, as described above. In order to make the composite insert 24 I may utilize the toe-lock 1 or' 2, but, preferablyfl may utilize the toe-lock, produced hereinabove before being trimmed off'around the marginal edges thereof. Accordingly, the untrimmed toe-lock 'a' or 2 is placed on the foot or` on thedcastproduced by the procedure of said Patent No..2,l77,304, or by the cast produced by the plaster compression'technique described hereinabove. Also, before-placing the said toelock on the foot orcast it is preferably provided with a thin coating of Vaseline on the lowermost ends of the several different interdigital extrusions 6,. which extend downwardly between the respective toes. Then, the underneath forward part of the foot is coated with a thickened latex. Thereupon, I provide a piece of jersey cloth 28 such as referred to above, powdered withplaster of Paris, and, placing it underneath the-forward part of the foot, I press it up with the lingers, into-the contours of the forward portion of the foot and especially so as to form the pyramid in the recesses between the toes respectively, and between the toes as a group and the metatarsal portion of the foot. I then coat-the jersey cloth 28 all over the underside with the latex. Beneath the said jersey cloth 28 and in the cavities therein formed as above, I now ll in the cavities therein formed as above with the felted latex mudrnade -as hereinabove described; However, the cubic granulas of felt -may be substituted by crumbs of foam-rubber, -Whicharein the form of pellets or granules, about the size of Grapenut grains, a product which is known on the marketunder the name .of foam Vrubber crumbs, and which-is av foamrubber, either of naturalor syntheticrubber, having very small or microscopic pockets therein.- Then, I pinch together the outer margins of the toe-lock and the jersey .cloth'28 all around thefront margins thereof so as to make substantially a horizontally extending web of the top and bottom fabrics, which are -then trimmed off with scissors around the foot margin.

of the same type "but which may be somewhat smaller than'the piece of cloth 28, is then placed over the top of the toe-lock 1 or 2 and below the piece 28,-which has had applied to the'inner surface of the cloth 29 thickened latex, which may be also trimmed olf around the .Instead of'the cover piece 29, however, I preferablyuse for this purpose the toe-portion of a sock 30, powdered with plaster of Paris, which is now placed over the top 27 and bottom 264 of the insert after the latter hasbeen coated on top and bottom with thickened latex. Preferably, also, the said cloth 29 and 30, after being applied to the afoot,'may be coatedwith thickened latex and thereafter dusted with powdered vplaster of In. either case, whether made with the cover 29 Paris. or the sock 30, the composite insert 24 is, whenpartially set, trimmed by'cutting off the same on -a verticalUline 31 extending through the middle of the big ltoe and on a vertical line 32 extending through the middle of the little toe, thus leaving the extreme outside of the foot, includ- -.-ing the lateral portions of said bigtoe and little toe, un-

Another cover Vpiece of jersey cloth 29 powdered withfplaster ofParis, 4K5V able vand plastic as it is a non-setting material, and would act substantially the same as a body of ordinary mud in a natural terrain, in ywhich the foot might be walking. Also, as shown in Fig. '14, VI'may vprovide a plurality of series-of Ventilating perforations 33 corresponding to the lines above andbelow the respective toes, in both the under portion 27 and the lower portion 26 thereof.

.Now, I can make a shoe having substantially no top and'bottom detail, at the portion of the foot comprising the toes and lthe adjoining metatarsal part of the foot, by placing this composite toe positioner, which includes the interdigital toe-separating elements 6 and pyramid 25, on the-foot or on an accurate cast of the foot made by any one of the applicants processes for making a castV of the foot, and the shoe maybe made thereon by any one of the-applicants molding'methodsas set forth in any of the applicants issued patents or applications for -Letters Patent relating thereto. .In

other words, with said .composite inserts 24 4and shoes i, able stock shoes of the ordinary kind to be worn on the feet with a `great degree of comfort and effectiveness because the insert occupies the front part of the shoe to support the foot against the non-fitting contours of such shoes when not molded to fit the feet.

Still another alternative procedure. maybe followed,

`by making a negativeplaster of VParis cast utilizing any of the procedures above referred to, fwith the toe-lock 1 or-2 on the foot orthe insert 24 lon the foot. y'When the negative `cast has been made-,theftoe-lockflor 2 or the insert-24 can be removed from the foot, After this has beendone, the plaster of Paris cream may bevpoured into 'the negative cast while notcontaining thetoe-lock 1 or 2 or the' insert 24 therein. This results'in the making-of a ypositive-cast which does not have thereon the top and bottom'detail contours ofthe ytoes and adjacent metatarsal vportion of the foot. By using this 'positive lcast so vmade I may build thereon a shoe by any of the molding methods described inany of my-preceding patents and applications for Letters `Patent relating to the molding or building of shoes. Moldedshoes made in this Way can then be worn on the feet having 'thereon the'toe-lock lor 2 or insert 24 and with or without a sock cover the same. lock or insert 'on the foot with 'or without a'sock over the same and withina simple pair of ordinary athletic shoes or` even rubbers, WithoutA danger'of 'the vforward part of the foot becoming deformed by the non-fitting shoe con'tours,because the-'said contours `do'not 'actually contact with: thel feet. This positioning of the toes and forwardv part of the foot is doubly effective when the interdigital elements 6 andthe pyramid 25, as a result of the molding operationfactually meet, 'although vit is not essential that'they'always meet. Also, the construction of theetoe-lock and insert gives such c'omplete control over the falangal portion ofthe foot as to provide means for producing orthopedic corrections vin a most effective way, which is comparable to orthodontestry. j: f

It will be understood that the insert 24, being of very flexible material, can be turned inside out so as'tofpermitthe inner surface to bel brushed out, but alsolso as to remove the superficial rubber in order to expose the fibers of the fabric, if desired. Similarly, if desired, the inner surface can be-provided with a further coating of latex, but if a latex or rubber surface is retained-'inside the composite insert 2'4, it is vpreferable-in wearing'to provide the same with 'a coating of powdered talc, or talcum powder, to prevent the-surface from being'adherent.

Still anotherway of obtaining a modified cast for use in shoe making is by putting the toe-lock 1 or 2 or com- Or it is feasible to wearsuch a toe-V 9 posite insert 24 on the foot. Then an athletic heavy weight sock of cottonA or Awool 41 is pulled over the foot. Meantime, a basin .ofi/ery soft plaster of Paris and water, fhavingthe consistency of milk, is prepared and with the hand this plaster of Paris milkis rubbed all over the sock repeatedly while at timesslightly resting the foot `on fth`e ball surface,`su`ch as lthe surface 14. In order to position the foot, for applying a heel if desired, the rear of the foot, when on a support, such as the surface 14, during this operation, may be supported upon a small lump of Plastelene 42. Thereupon, I provide a number of pieces, generally about twentyfour,.each having a width of 2,fof plaster ofl vParis bandages 43, which maybe cheesecloth having unset plaster of Paris vdistributed throughout the meshes of the cloth. These plaster of Paris bandages are `wound around all over the sock 41, after each bandage has been dipped in waterf vThe winding of these bandages on the foot may be accomplished with or without tension but for making certain vtypes of shoes, as for skating, dancing` or athletics, or even style production, the bandages 43 can be tightly wound around the foot, but care should be taken not to wind the bandages so tight as to injure the foot. Also, for skating and dancing shoes, the plaster of Paris bandages are preferably wrapped considerably higher around the calf of the leg. When the plaster of Paris in the bandages 43 has set, which is in about fifteen to twenty minutes after being dipped in water and applied to the foot, I may make a slit 44 down the front of the foot through said bandages with surgical scissors, after which the negative thus produced, by the plaster of Paris which has partly set preferably, is removed from the foot and then one long strip of wet but unset plaster of Paris bandage is wrapped around the shoe. This composite plaster of Paris bandage now forms a negative in which a positive plaster of Paris cast-may be made after rst applying to the interior thereof a water solution of silicate of sodium to provide a good separation from the positive. Thereupon, I pour into the negative a plaster of Paris and water mixture having a consistency of cream, to make the positive cast.

While I have-described my invention above in detail I wish it to be understood that many changes may be made therein without departing from the spirit of the same.

I claim: t

l. A cast conforming to foot-form contours embodying in the cast the conformation of toes separated by an interdigital toe separator having on said separator an underneath toe recess pyramid.

2. A negative cast conforming to the contours of a foot-form embodying in the front portion thereof a hollow toe section of slightly greater volume than that occupied by the toes, said volume being just large enough to receive the toes with an interdigital toe separator positioned thereon which separator includes a sheet of material that covers a plurality of said toes.

3. A negative cast conforming to foot-form contours embodying in the cast the conformation of toes separated by an interdigital toe separator having on said separator an underneath toe recess pyramid.

4. A positive cast conforming to foot-form contours embodying in the cast the conformation of toes separated by an interdigital toe separator having on said separator an underneath toe recess pyramid.

5. The process which comprises making a cast by applying a toe-positioner to a foot so as to separate toes thereon, applying pressure to the under surface of the foot to give the foot a desired position, applying to the opposite side of the foot a material adapted to set while conforming to the contours of said opposite portion of the foot as determined by said toe-positioner, allowing the material to harden, removing the pressure from the first mentioned portion of the foot and pressing said first mentionedportion ofthe foot in a soft viscous material adapted to set, while said hardened mass of material remains on said opposite side of the foot.

6. The process which comprises making a cast by applying a toe-positioner to a foot so as to separate toes thereon, applying pressure to the under surface ofthe foot by a `foot-supporter to give the foot a desired position,applying to the opposite iside of the foot a material adapted to set while conforming to the contours of said opposite portion of the foot as determined by said toepositioner, allowing the'material to harden, removing the pressure from the Vfirst mentioned portion of the foot and pressing said first mentioned portion of the foot in a soft viscous material adapted to set, while said hardened mass of material remains o n said opposite side of the foot. t

7. In the manufacture of Ya negative cast having a hollow toe section therein of volume slightly greater than that of the toes, which hollow toe section is made just large enough to receive the toes with an interdigital toe separator positioned thereon, which separator includes a sheet 4of material that covers a plurality of said toes, the methodwhich'comprises the Asteps of separating the toes on a foot-form and covering a plurality oftoes with a sheet of material by placing the toesepara'tor on suchV foot-form, applying a molding material to said foot-form which material is adapted to set and form a cast thereof, and maintaining the toe separator in place on the footform while such molding material hardens to prevent the molding material from penetrating into the spaces between adjacent toes.

8.- The method described in claim 7 which includes the step of molding a positive cast in the negative cast with said toe separator in place therein.

9. The method described in claim 7 which includes the steps of applying a plaster of Paris slurry to the said foot-form as the molding material and then allowing the plaster to harden to form a negative cast thereon.

10. The process described in claim 7 which includes the steps of applying plaster of Paris bandages to said foot-form as the molding material and then allowing the plaster bandages to harden to form the cast.

ll. In the manufacture of a negative cast having a hollow toe section therein of volume slightly greater than that of the toes, which hollow toe section is made just large enough to receive the toes with an interdigital toe separator positioned thereon, which separator includes a sheet of material that covers a plurality of said toes, the method which comprises the steps of separating the toes on a foot and covering a plurality of the toes with a sheet of material by placing the toe separator on the foot, applying a material to said foot which material is adapted to set and form a cast thereof, and maintaining the toe separator in place on the foot while such molding material hardens to prevent the molding material from penetrating into the spaces between adjacent toes.

12. 'Ihe process which comprises placing the lower portion of the foot having a toe-positioner separating toes thereon in a molding material, putting a layer of separating material on the molding material and applying a moldable material to the top of the foot to form an upper negative while supported in said molding material.

13. The process which comprises placing the lower portion of the foot having a toe-positioner separating toes thereon in a molding material, putting a layer of separating material on the molding material, applying a moldable material to the top of the foot to form an upper negative while supported in said molding material, then separating the upper and lower negatives and separating the upper negative into sections, joining the negative portions together and making a positive therein.

14. 'Ihe process which comprises suspending `the lower portion of the foot having a toe positioner separating toes thereon in a molding material, putting a layer of separating material on the molding material and applying 1l a 4moldable material vto the top ofthe foot to form ah u'pper negative while pressing onV said molding material.

15. The process which comprises suspending' the lower portion of the foot having a' toe-positioner separating toes thereon in a molding material, putting a layer of separating material on the molding material, applying a moldable material to the top of the foot to form an upper negative while pressing on said molding materiaL'then separating the upper and lower negatives and separating the upper negative into sections, joining the negative portions together and making a positive therein.

16. The method of making a cast which includes the steps of separating the toes of a foot by applying a toe positioner thereon, pressing the bottom of the foot against a' spherical surface to give the bottom of the foot curvature which simulates the natural curvature of the foot when heldin space, applying a material to the upper portion of the foot which material is adapted to set while conforming to the contours of said upper portion of the foot as determinedY by said toe positioner, allowing the material to set and then pressing the lower portion of the foot into a mass of material adapted to set and form a cast while said material remains in place on the upper portion of the foot.

the toes of the foot by applying a toe positioner thereon, placing the lower portion ofthe foot in a mass of material adapted to set while it conforms to4 the contours of the foot with the toe positioner in place thereon, allowing the material to set to form a self-sustaining cast, thereafter applying a material to the upper portion of said foot which material is adapted to set and form a cast and then allowing such material to set on theupper portion of the foot to form a negative cast thereof.

References Cited in the le of this patent UNITED STATES PATENTS Larson Novf. 1, 1 92'7 Murray a v a Oct. 24,I 1939 

